Laser-Removable Separation Layer for Partable Structural Laminates
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Solution Overview
Problem
Existing adhesives used in electronic devices for long-term bonding make it difficult to separate components without causing damage, especially in small electronic devices, hindering repair and recycling efforts.
Innovation Solution
A laminate comprising a first adhesive layer, a separation layer with laser-sensitive pigments, and a second adhesive layer, allowing separation through controlled laser ablation of the separation layer to facilitate clean and reliable separation of bonded components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive layers are used to bond components for long-term durability, then bond strength and product lifespan are improved, but separation becomes difficult and may damage components
Solution Approach 1:
The adhesive system is segmented into multiple layers: a first adhesive layer, a separation layer in between, and a second adhesive layer. This segmentation allows the bond to be strong during use while enabling controlled separation by targeting the intermediate separation layer for laser removal.
Solution Approach 2:
A separation layer acts as an intermediary between the two adhesive layers. This intermediate layer is designed to be removable by laser irradiation, serving as a controlled weak point that enables separation without damaging the adhesive layers or bonded components.
2Stability of the object's composition
If conventional adhesive bonding is used, then long-term structural integrity is achieved, but recycling and disassembly become problematic
Solution Approach 1:
The separation layer is pre-positioned between the adhesive layers during manufacturing, creating a built-in separation mechanism. This preliminary action enables future disassembly and recycling without requiring new tools or processes, as the separation capability is already embedded in the laminate structure.
Solution Approach 2:
The separation layer undergoes parameter changes when exposed to laser irradiation, transitioning from a bonded state to a removed state. This parameter change (removability under specific conditions) allows the laminate to maintain structural integrity during normal use while enabling easy separation for recycling when needed.
3Duration of action of stationary object
If strong adhesive bonds are formed, then component durability is improved, but separation force required increases causing potential damage
Solution Approach 1:
The separation layer is extracted or removed from the bonded assembly through laser irradiation before separation occurs. By taking out this intermediate layer, the strong adhesive bonds are released without requiring high separation forces, preventing damage to the permanently bonded components.
Solution Approach 2:
The mechanical separation process is substituted with a laser-based removal process. Instead of applying mechanical force to separate the bonded components, laser energy is used to selectively remove the separation layer, replacing high-force mechanical action with low-force optical energy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable and efficient separation of long-term bonded components, preserving the integrity of undamaged parts and supporting repair and recycling processes.
Implementation Method 1
the separation layer consists of a metal which is at least partly removable by laser irradiation
Data Source
AI summary
Laminates separated after long-term bonding and methods for separating laminates after long-term bonding is provided. The laminates comprise (a) a first adhesive layer, (b) a separation layer, and (c) a second adhesive layer, wherein the separation layer comprises a laser-sensitive pigment which at the same time is coloring, and so preferably a black coloration is produced, and consists of a cured coating material, preferably an electron beam-cured or UV-cured coating material, which is at least partly removable by laser irradiation. The first adhesive layer and/or the second adhesive layer may be laser beam-translucent or may comprise a reactive or latent-reactive adhesive.